Triumph 99-0906 1970 Tr25w Trophy 250 X

REPLACEMENT
PARTS CATALOGUE
THtrtrFilY
TR25
258
W 25O c.c. (15 cu. ins.)
I97O MODELS
www.bsaunitsingles.com
REPLACEMENT
PA RTS
CATALOGUE
TR 25W
TRIUMPH ENGINEERING COMPANY LIMITED

MERIDEN WO RKS ALLESLEY .COVENTRY ENGLAND
TELEPHONE MERIDEN 33I TELEX 3'305 TELEGRAMS "TRUSTY, COVENTRY'
P..t No. 99-0906

PU BLISHED SEPIE MBER 1 9 69
TRIUMPH GUARANTEE
'1. In this Guarantee the word "machine" refers to the motor cycle, scooter, motor cycle combination
or sidecar as the case may be, purchased by the Purchaser.
2. ln order to obtain the benefit of this Guarantee, the Purchaser must have correctly completed the
registration form and returned it to us within fourteen days of the purchase.
3. We will supply, free of charge, a new part in exchange for, or, if we consider repair sumcient, will
repair free of charge any part proved within six months of the date of purchase of any new machine,
(three months overseas) or within three months of its renewal or repair in the case of a part already
renewed or repaired, to be defective by reason of our faulty workmanship or materials. We do not
undertake to bear the cost offitting such new or repaired part or accessory.
.4 Any part considered to be defective must be sent to our Works, carriage paid, accompanied by the
following information :-
(a) Name of purchaser and his address;
(b) Date of purchase of machine;
(c) Name of dealer from whom the purchase was made;
(d) Engine number and model.
5. This Guarantee shall not extend to defects or damage appearing after misuse, neglect, abnormal stress
or strain, or the incorporation or afflxing of unsuitable attachments or parts and in Particular:-
(a) Hiring out;
(b) Racing and Com petitions;
(c) Adaptation or alteration of any part or parts after leaving our Works;
(d) The attaching ofa sidecar in a manner not approved by us or to an unsuitable
motor cycle.
This Guarantee shall not extend to machines whose trade mark, name or manufacturing number has
been altered or removed, or in which has been used any part not supplied or approved by us, or to
tyres, saddles, chains, speedometers, revolution counters and electrical equipment or to parts supplied
to the order of the Purchaser and different from our standard specification.
6. Our liability and that ofour dealer who sells the machine, whall be limited to that set out in this guarantee,
and not other claims including claims for consequential damage or injury to person or property, shall
be admissable. All other conditions and warranties statutory or otherwise and whether express or
implied are hereby exctuded and no guarantee other than that expressly herein contained applies to
the machine to which this Guarantee relates or any accessory or part theregf.
7. We reserve the right to modify or deviate from the Published Specification without notice.
THE FITTING OF ANY COMPONENTS WHICH ARE NOT APPROVED BY THE

MAN UFACTURER INVALIDATES THE GUARANTEE
REPAIRS GUARANTEE
1. Whilst the highest standard of workmanship and materials is aimed at, we canno! accept liability for
any defects appearing more than three months after the machine, assembly or component has left our
Works after being repaired.
2. We will repair or replace at our option free of charge any defective work, materials or parts relating
to the repairs carried out by us appearing within that time but shall not be under any further or other
liability for any other loss or damage whether direct or consequential and our liability shall be limited
to the cost of so making good. We do not undertake to bear the cost of fitting any replacement or
repaired part.
3. We do not accept liability in respect of parts of proprietary manufacture, e.g. tyres, saddles, chains,
speedometers, revolution counters and electrical equipment which may be used by us in effecting a
repair. AII other conditions and warranties statutory or otherwise express or implied are hereby excluded.
t-
INDEX
Poge Poge
AIR FILTER ... 59 OIL PUMP ... 15

ALTERNATOR ... 15, 23 OIL RELEASE VALVE . 13
OIL TANK ... 31
BATTERY CARRIER... 15
PILLION FOOTRESTS ... 33

CARBURETOR ... 59 PISTON ... 9, 1'l
CARTON PACKS ... 7 PRII'4ARY CHAINCASE ... 23
CHAINGUARD ... 29 PROP STAND ... 29
CHAINS ... 23, 41
CLUTCH ... 23
cotL ... 53 REAR PANELS ... 31
CONTACT BREAKER ... 71 REAR WHEEL ...41,43
CONTROL CABLES... ... 49 RECTIFIER ...53,55
CONTROL LEVERS ... ... 49 REFLECTORS ... ... ... 53
CRANKCASE... ... ... 13, 15
CRAN KSHAFT ... 9,11
CYLINDER HEAD ... 9, 11
SPARK PLUGS ... 9, 11
SPEEDOMETER ... 51
STEERING RACES ... 35, 37
EXHAUST PIPES 3't
SUSPENSION UNITS ... 29
swtTcHEs ... 53, 5s
FE N DERS ... 45
FOOTRESTS ... ...
FRAME... ... 25 TACHOIVlETER ... 5'1
FRONT FORKS ...35,37 TAIL LAMP ... 52

FRONT WHEEL ... 39 TII.lING GEARS ,,. I)
TIMING COVERS 17,'t9,11
GAS TANK 47
TOOLKIT ... 57
GASKET SETS ... 7

TWINSEAT ... 47
GEARBOX 17, 't9, 11
VALVES ... 9, 1'l

HANDLEBARS 49
HEADLAMP ... ... 52
HORN... WIRING HARNESS ... ()
53
MUFFLER 31 ZENER DIODE 55
TROPHY 250 TECHNICAL D ATA
Bore and stroke ... 67 x 70 mm.
Capacity ... -.. 249 c.c.
Compression ratio 9.6:1
Sparking plug Champion N3
Carburetor Amal Concentric .928

Choke size 28 mm.
Main jet ... 160
Need le jet ''106
Need le Standard
Throttle valve No. 3
Gearbox sprocket 15 teeth
Final Drive Sprocket 52 teeth East Coast

49 teeth West Coast
Chains Front $ in. x S in. Duplex x 70 links
Rear ; in. x I in. x 10'1 links East Coast
I in. x + in. x 99 links Vy'est Coast
Capacities ... ... Fuel tank ... 3.916 galls. U.S.
Oil tank ... 6 Pints
Gearbox ... + pint
Primary chaincase I pint
Front forks (each leg) ... + pint
Brakes Front and rear diameter 7 in.
Tyre size ... ... Front 3.25 x 18

Rear 4.00 x 18
TRIUMPH SPARES
HO\/V TO ORDER. Every part is indicated by a number, and this should be quoted together with
the description. ln order to assist customers, dimensions have been given in many cases where parts are
similar. Parts where possible have been listed in order of assem bly and a n u m ber of the illustrations show the
assembly order also. With these aids, there should be no difficulty in identifying the parts you require.
ALWAYS HEAD YOUR ORDER WITH THE ENGINE NUMBER, STAMPED ON THE LEFT SIDE OF
THE ENGINE JUST BELOW THE CYLINDER, TOGETHER WITH THE PREFIX LETTERS.
WHERE TO OBTAIN, Triumph Spare Parts can only be obtained from an authorised Triumph
Dealer, and we recommend our customers to place their orders with the Triumph Dealer in their district.
When parts not usually asked for are required, and for which the Dealer may have to write or obtain specially,
the postage or carriaSe incurred becomes payable.
Customers are warned against the risk incurred by purchasing parts that are not ofgenuine Triumph
manufacture. This risk is eliminated if parts are ordered as instructed from recognised Dealers.
PROPRIETARY GROUP
Ancillary equipment which is fitted to our motor cycies is ofthe highest quality and is guaranteed by
the manufacturers and not by ourselves. Any repairs or claims should be directed to the actual makers
or their local agents who will always give owners every possible assistance. The following are the addresses
of the various manufacturers'-
CARBURETORS. The Avon lndia Rubber Co. Ltd.,

Messrs. Amal Ltd., f4elksham,
Holdford Road, Wilts.
Witton,
Birmingham,6. SPARKING PLUGS.
Champion Sparking Plug Co. Ltd.,
CHAINS. Feltham,
Renold Ltd., M iddlesex.
Wythenshawe,
Manchester. SPEEDO M ETERS.
Messrs. Smiths lndustries Ltd.,
ELECTRICAL E@UIPMENT, Cricklewood Works,
Messrs. J. Lucas Ltd., London, N.W.2.
Gt. Hampton Street,
Birmingham, lS. SUSPENSION UNITS.
Messrs. Girling Ltd.,
TYRES. Birmingham Road,
Dun lop Rubber Co. Lto., West Bromwich,
Fort Dunlop, Staffordshire.
Birmingham,24.
HOW TO USE
THIS PARTS CATALOGUE
Consult the index on Page 3 for the parts or group of parts which you wish to locate.
List the quantities required as single units; do not ask for "2 pairs" or "3 dozen".
Items marked "reference only" are not available from the factory.
Proprietary components e.8. electrical equipment, carburetors, suspension units etc. are listed in the flrst
column under Triumph part numbers (prefixed either D- or 99-) wherever they are stocked at the
factory. lf proprietary parts are listed only under manufacturers part numbers, they are not available from
the factory.
PLEASE NOTE
THROUGHOUT THIS LIST, ASSEMBLIES ARE PRINTED IN CAPITALS AND THE COMPONENTS
INCLUDED IN THAT ASSEI4BLY ARE INDENTED IN THE DESCRIPTION COLU14N, REVERTING
TO THE ORIGINAL ALIGNMENT WHEN THE ASSEI4BLY IS COMPLETE. TO ORDER THE COMPLETE
ASSEMBLY IT IS NECESSARY ONLY TO QUOTE THE ASSEIYBLY NUI'4BER. ANY COMPONENT
PARTS LISTED MAY ALSO BE OBTAINED SEPARATELY IF REQUIRED.
SPECIAL WORKSHOP TOOLS

A COMPLETE LIST OF WORKSHOP TOOLS CAN BE MADE AVAILABLE BY EITHER CONTACTING
YOUR DEALER OR APPLYING DIRECT TO THE DISTRIBUTOR. IN MOST CASES THESE TOOLS ARE
VERY COSTLY AS THEY ARE II4ADE ENTIRELY FOR WORKSHOP USE, AND THEREFORE, IT IS NOT
RECOI"II"lENDED THAT THE PRIVATE OWNER PURCHASES THE TOOLS IN ORDER TO AID SERVICING
THE MACHINE ONCE OR TWICE ONLY. IN THESE CIRCUI,ISTANCES IT IS FAR MORE ECONOMICAL
TO GET IN TOUCH WITH A RECOGNISED DEALER.
UNIFIED TH READ FORM

NEW PARTS HAVING THREADED FIXINGS INTRODUCED IN THIS CATALOGUE HAVE THE UNIFIED
FORI4 OF SCREW THREADS. THIS CHANGEOVER WILL BE CONTINUED AS AND WHEN NEW PARTS
ARE INTRODUCED. EVEN WHERE PARTS ARE SIMILAR IN APPEARANCE NEW PART NUMBERS
WILL BE ALLOCATED TO IDENTIFY THE UNIFIED THREADS. ALL NUTS, BOLTS AND STUDS HAVING
THIS THREAD ARE IDENTIFIED BY MARKINGS. BOLTS HAVE A CIRCULAR RECESS IN THEIR HEADS,
STUDS A CIRCULAR GROOVE ON THE END, AND NUTS HAVE INTERLOCKING CIRCLES ON IHE
SIDE.
CARTO N PACK LIST
The following sub-assemblies are supplied in carron packs under the part numberstated. The contents
ofthese carton packs are preserved and will not deterlorate under adverse conditions.
PISTON (complete with rings, gudgeon pin and circlips). These are in effect,carton pack,
assemblies.
E7998 9.6 : I C.R. STANDARD SIZE

E8277 9.6 : 1 C.R. 0.020 in. oversize
E8773 9.6 : 'l C.R. 0.040 in. oversize
OVERHAUL GASKET SET 99-0031
DECOKE GASKET SET 99-0040
PA RTS VARYING FROM STANDARD SIZE
The following are the part numbers of piston rings to suit oversizes of +0.020 in. and +0.040 in. These
rings are no longer available in carton packs:
PISTON RINGS 1 E8177 Top compression ring

(0.020 in. oversize) 1 E90'17 I'4idd le compression ring
1 E9021 Scraper ring
PISTON RINGS 1 E8278 Top compression ring

(0.040 in. oversize) 1 E9018 lYidd Ie compression ring
1 E9022 Scraper ring
Big end bearing undersizes 0.010 in. Part Number E6068/10

0.020 in. Part Number E6068/20
0.030 in. Part Number E6068/30
68
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39
27
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-4W l\
,ua
NN
o.. l,40
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Fig. l. CYLINDER HEAD, BARREL AND CRANKSHAFT
Ref. No. Port No. DESCR/PflON QUANTITY
CYLINDER HEAD, BARREL AND CRANKSHAFT

'l E9848 CAMSHAFT AND FLYWHEEL ASSEMBLY I
z E9849 C ran kshaft Reference only

3 E9906 FLYWHEEL DRIVE SIDE Reference only
4 E9907 FLYWHEEL TII'4ING SIDE Reference only
5 E8036 Screwed plug 1
6 E8032 Flywheel bolts (1$ in. U.H.) 4
7 E8033 Flywheel bolts (2 in. U.H.) 4
E8037 Wash e r 8
9 E8038 Shim (0.0'10in.) ... A.R.
9 E8039 Shim (0.015 in.) ... A.R.
10 E1580 Crankshaft pinion key ... ... 1
'11 E8144 Rotor key 'l
12 E8836 CONNECTING ROD 1
13 E3705 Connecting rod bolt 7
14 E2922 Self locking nut 2
15 E6068 Connecting rod big end bush (available in undersizes of
0.010 in., 0.020 in.,0.030 in.) 2 halves
D911 Sparking plug N3 'l
'17 E7998 *PISTON COMPLETE
1
18 E8276 Plain compression ring 1
19 E6838 Taper compression ring 1
20 E6839 Oil control ring 1
21 WE2O3E Gudgeon pin 1
22 wE479 Circlip 2
23 E9263 Cylinder barrel 1
24 E7728 Cylinder base washer 1
25 E8053 Push rod (exhaust) 1
25 E8055 Push rod (in let) 1
26 E7739 Tappet 7
27 E8008 Cylinder (2+"-in o:A) 2
16 E8196 Stud nut 1i:*''::o 2
29 E8215 7
30 E8197 CYLINDER HEAD 1
E8228 Stud (2+ in. O.A.) 7
32 E8229 Stud (3 in. O.A.) 2
33 E7996 Stud (3+ in. O.A.) 3
34 E8010 Dowel 2
35 E8080 Stud (21{ in. O.A.) 2
36 E8227 Carburetor stud (1$ in. O.A.) 7
37 E8725 ValYe gu ide (inlet) 1
37 E't1227 Service size valve guide -f.002 in. 1
37 E1'1228 Service size valve guide +.015 in. 1
38 E8226 Valve gu ide (exhausr) 1
38 El1229 Service size valve guide +.002 in. 1
38 E',t1230 Service size valve guide f .0'15 in. 1
39 E8081 Cylinder head gasket I
40 E8137 Carburetor stud nut 2
41 E8136 Carburetor flange washer" 1
42 E7820 Distance piece ,.. 1
*Refer page 7 for oversizes.
63 65
uo @uu
6) g
se @^
vaz \43
6a
67R
o@* g\
6P
6\@ ,, "'
'1,flv
,' --70 ,'
zs u
% 34 28
'&
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NN
-l ,",U
6) 42
@L
' -22
Fis. l. CYLINDER HEAD, BARREL AND CRANKSHAFT
10
Ref, No. Port No. DESCRIPflON QUANI/IY
CYLIN DER HEAD, BARREL AND CRANKSHAFT continued
43 E7911 Rocker box ... I

44 E7858 Rocker box gasket ... 1
45 E7787 Rocker spindle ... ... ... 2
46 E7790 INLET ROCKER ... 1
47 E7791 EXHAUST ROCKER ... ... ... 'l
48 E1483 Ball end ... 2
49 E'!575 Thrust washer ... ... .. 2
50 E1330 Thrust washer .., ... 2
JI E8952 lnspection coyer... ... 1
52 E808s Gasket ...
...
1
53 E8086 Screw (]f in. U.H.) z
54 E11165 Top collar ... 7
55 El1166 Split collet ... 4 halves
55 E8112 lnlet valve ... 1
57 E7777 Exhaust valve ... ,1
58 Dt002 PIug cover ... 1

59 14-0403 Locknut ... ... 2
60
61
s25-2
E8952
Washer ...
lnspection cap
... z
2
62 E8085 Washer ... ... 7
63 E8087 Nut ... 1,
64 E8088 Washer ... ... 7
65 E8089 Nut ... 7
66 E8072 Washer ... 7
67 E8082 Union ... I
68 E8083 Fibre washer ... 1
69 E8105 ROCKER FEED PIPE ASSEMBLY ... 1
70 E8106 Oil feed pipe (26f in. long) ... 1
71 E8111 Clip... ... 1
72 E8107 Nipple ... I
73 E81 10 U nion nut ... ... 1
74 E8113 Bottom cup ... 2
75 E8114 Valve spring-outer ... ... 2
76 E811s Valve spring-lnner ... ... 7
11
m'-.-.o
@'-31
6<T
90
57 54
t 47
@-:77
@r--78
w--,o
fFt
q&=68
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ryffi-"
,r l&
\t7
18
66
65
Fig.2. CRANKCASE
'12-
Ref. No. Port No. DESCR'PI/ON QUANIi I}'
CRANKCASE
1 E11'119 CRANKCASE 1
2 E8006 Cylinder securint stud 2

3 s1889 Crankcase top stud (2!| in. O.A.) 2
4 s1890 Crankcase rear stud (21{ in. O.A.) 2
,|
5 E8009 Hollow dowel
6 E8011 Solid dowel ... ... 2
7 1+1401 Sum p stud ... ... 4
I E8003 l4ain bearing (ball-journal) 1
8A E9974 Main bearing (roller bearing) 1
9 E8025 Oil seal left main bearint ... ... 1
10 s1894 Generator stud rear, short hexagon 1zg i".1 'l

11 s1895 Generator stud front, long hexagon (2{i rn.) 'l
12 s1896 Generator stud bottom (2{; in.) 1
13 E8315 Camshaft bush 1

't4 E8014 Mainshaft bearing 1
15 E8015 Mainshaft oil seal ... 1
't6 E6026 Oil seal circlip 1
17 E8010 Hollow dowel 1
18 s1891 Oil union stud ... 1
19 E8017 Scavenge pipe 1
20 s1893 Oil pump stud ... 2
21 E8022 Hollow dowel 2
s1857 Gearbox drain plug 1
73 12697 "O" ring 1
24 sl872 Timint hole plut... 'l

25 E8896 Washer hole plug 'l
26 E9384 Sealing plare 1
27 E8256 Sealing washer ... ... 1

28 T1'150 Screw 2
29 s1892 Bolt (1+ in. U.H.) 3
30 14 0303 Cylinder securing nut ... 4
31 E8135 Washer ... 4
32 14-0307 Nut 4
E8088 Washer ... 7
34 E8065 Sump cover 1
34A E9979 Filter 1
E8070 Gasket 1
36 E807'1 Plain washer 4

14-1901 Nyloc nut 4
38 OIL RELEASE VALVE... 'l
39 E7590 Valve body ... ... 1
40 GS251 Piston 1
41 E6596 caP ... 1
42 GS254 Fibre washer 1
43 E11156 l'4ain spring... ... 1
44 E9737 Joint washer 1
45 E8124 Non-return valve spring 'l

46 H2704 Valve ball... ... 'l
47 s1898 Valve screw 1
48 D2133 Oil pressure switch Alternative
'13
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3A // 41'
,-of43 >.\
tw*nk",
oo \-iS)
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SP-ou 77
/ai
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&"'
q_
LqH 74
)[lil'
64 ryffi"
23-@
22 (g
\r--ll
Fig.2. CRANKCASE
14
Ref. No. Port No. DESCR/PTiON QUANI/TY
CRANKCASE continued
49 D2045 Cover for oil switch 1
50 12695 Dipsrick ... 1
51 T948 Dipsticl( washer ...

... 1
52 E8147 Clip for alcernaror lead grommec 1
53 E8148 Alrernator lead grom met 1
54 E3789 Orl seal housing ... ... 1
55 E3832 G ask ct 1
56 E3833 Oil seal 1
57 E3821 Screw 6
58 E8179 Chain oiler 1
59 E8173 R: bber pipe 1
60 s1985 Sru d 1
61 E8072 Washer ... 1
62 14-1901 Nyloc nut 1
53 E8127 O'l pipcs and unron block 1
64 E8259 ''O" ring ... .. 2

65 14-0302 Un ion nut 1
66 E8134 Serrated washer... ... 1
67 E111 33 OIL PUI,IP COMPLETE 1
68 E11139 Spind le housing 1
69 E11'147 Spindle 1
70 E8094 Spind le gear 1
71 E8095 gear-driven ...

Feed ... 1
77 E1't143 Scavenge gear-driving 'l

73 E8097 Scavenge gear-driven 1
74 El1147 Driven gear spindle 'l
75 E8099 Bottom plate 1
76 E8100 Screw 4
77 E8071 Spindle gear nut 1
78 F9041 Spindle gear washer 1
79 E8103 Gasket 1
80 1+190'.1 Hold ing nut 1

8t E8104 Washe r 7
82 E11276 Camshafc c/w pinion 1
83 E8041 Drive tear I
84 E997s Distance washer... ... 1
85 E8040 Cran l<shaft pinion 1
86 E8043 Lockwasher 1
87 w1798 Nut 1
88 E8140 Distance piece C325 in. thick)... A.R.

88 E8141 Distance piece (3'10 in. thick)... A.R.
88 E8142 Distance piece (295 in. thick)..- A.R.
89 E8139 Engine sprocket (23T) ... 1
90 E8184 Chain tensioner ... ... 1
91 E8143 Distance piece ... ... 1
92 1+1901 Nut 3
93 E8072 Washer ... 3
94 99-0739 Rotor (5421 3901) 1
95 E8274 Tab washer 1
96 E8146 Nut 1
15
37
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[[w 34
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, 53.54 (.Y'
\,2
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r -99
/il .ru1OO
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\/ 27
--79
19 @r- ,.94 \6
_*qD'
J- 23
76
)?
(, 24
a\
13iv\
N. I v
A) ",i
/Y
72 I
15 30
70J
/73
+-97 2ts
104
107
v/d 106
P"EK.--
_^^
-"e xo /lo5 103
90
64
63
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A
t-:r
Ge tlr/ a3
62
Fig.3. GEAR CLuSTER AND TIMING COVERS
't6
t-
Ref, No. Port No. DESCR/PIlON QUANTITY
GEAR CLUSTER AND TIMING COVERS

'l r2661 MAINSHAFT COMPLETE WITH BUSH 1
2 r1391 Pushrod bush 'l
3 I3872 HrGH GEAR (22T) I
T275i lligh gear bush 2
5 E8015 Mainshaft oil seal 'l
6 E8014 Mainshaft bearing 1
7 T2678 Th rust washer (093 in.)
1
7 12679 Th rust washer (098 in.)
A.R.
7 T2680 Thrust washer (.103 in.) A.R.
8 T3876 Mainshaft second gear (21T) ... 1
9 12664 Spacer (075 in.)... A.R.
9 r2:665 Spacer (070 in.) ... A,R.
9 r2666 Spacer (080 in.) ...
A.R.
10 r2662 Mainshaft third gear (24T)
11 r7663 Mainshaft low gear (16T)
12 E8151 l'4ainshaft bearing
13 E8152 Bearing circlip ... ... 1
14 T2677 Felt washer 'l
15 T2685 Lockwasher 'l
tb T2686 l'4ainshaft nut
1
't7 r2667 Layshaft and high gear (14T) ... ... I
18 17671 Thrust washer (084 in.) 1
'18 r2672 Thrust washer (079 in.) A.R.
't9 E8005 Layshaft bearing ... 1
20 T2668 Layshaft second gear (22T)
1
21 n669 Layshaft circlip ... 'l
22 r3877 Layshaft third gear (19T)
1
23 T3874 LAYSHAFT tOW GEAR COMPLETE
24 r2757
Qn\ 1
Low gear bush 1
75 17670 Spacing shim
1
26 T2733 Clutch push rod ... 'l
27 r2750 Clutch lever complete ... 'l
28 T7699 Clutch operaring rack ... 1
29 r2700 Clutch operating pin ion 1
30 E801 9 Thrust ball 1
31 r2765 Gearbox sprocket (15T) I
31 T7701 Gearbox sprocket (16T) Alternat ive
31 r2766 Gearbox sprocket (1/ I) Alternative
32 r2707 Tabwasher 1
11$4 Nut 1
34 T1164 Gear change pedal 1
35 T2450 Pedal rubber
1
36 12703 Pedal bolt (+ in. U.H.)
1
37 r2692 GEARCHANGE QUADRANT 1
38 T',t277 Sprint rivet... 7
39 rT07 Keeper plate 1
40 T2435 Screw 1
41 T2106 Spring 2
42 T2105 Plu nger
2
43 T'1109 Return spring 1
44 T3854 Selector fork-main shaft
1
17
I
34
\ ,"^,
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t( ),4
auJ '
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Aat 2zl
ty2
9A
-79
\6
76
77 )P
is / \,i "Ku
K,
,1 T 15 30
7.,l
/73 g-97
CIfl
62
Fig.3. GEAR CLUSTER AND TIMING COVERS
18
Ref. No. Port No. DESCR/PTlON QUANTiIY
GEAR CLUSTER AND TIMING COVERS continued
44 r2689 Selector fork-lay shaft

45 T3763 Anchor bolt
46 T2688 Selector spindle ... ...
47 T3850 Camplate ... ...
48 T1069 Camplate spindle
Not illus. D2.724 Splitpin ...
49 r2691 lndex spring
50 r1749 Spring backing ... ...
51 r1076 Screw
52 T1180 Lockplate...
53 E8150 Camshaft bush ... ...
54 E3172 P"g
55 E8153 Camshaft oil seal
56 E8154 Crankshaft T/S oil seal ...
57 E8157 Oil seal circlip ... ...
58 E8155 Cable grommet ... ...
59 r2763 KICKSTART CRANK COMPLETE
60 r2:/74 Kickstart fold ing pedal
61 T2330 Pedal rubber ... ...
6Z T1169 Pivot bolt (1 in. U.H.)
63 11167 S pring
64 H2704 Steel ball

65 r2704 Cotter Pin
66 r2705 Cotter washer ... ...
67 T2706 Cotter nut
68 r4070 KICKSTART SPINDLE...
69 E8005 Needle roller
70 T2687 Return spring
71 r37 64 Anchor pin
72 17657 Kickstart stop
73 T2658 Circlip
74 r2681 Kickstart ratchet
75 12682 Bu sh
76 T2683 Pinion
77 r7684 Spring
78 E8172 Contact breaker cliP
79 E8072 Washer ...
80 E8737 Contact breaker cover
81 E7882 Gasket
8Z E7354 Screw (+ in. U.H.)
83 E8'165 Serrated washer
84 E9433 OUTER TIMING COVER
85 E8010 Hollow dowel
86 r2641 Kickstart oil seal ...
87 r7647 Bush...
88 1+66't2 Outer cover screw (2 in. U.H.)
89 1+6611 Outer cover screw (1f, in. U.H.)
90 1+6610 Outer cover screw (1{ in. U.H.)
91 E8169 Outer cover screw (f in. U.H.)
92 1+6606 Outer cover screw (f, in. U.H.)
93 't+6614 Outer cover screw (2| in. U.H.)
19
45
50
3
34
/
\ ,.^-
D1.*
101 C&' R
d &----.u 35 I
\
V
(/AL_ss
_es
/r\Hloo
tk 7s
a 27
19
@_rn I
23
w*," 77
\6
W
ao{
6R
* 24
\\
v
K^,1
'ls 30
'1 .,n I
73
g-sz
a7
64
63
P
62
59
Fig. 3. GEAR CLUSTER AND TIMING COVERS
Ref, No. Port No. DESCR/PIlON QUANI/TT
GEAR CLUSTER AND TIMING COVERS continueo
94 El1061 lnner timin8 cover 1

95 r1026 Breather tube 1
96 E8162 Screwed plug 1
97 E9526 Screwed plug (socket head) 1
98 14 6608 lnner cover screw (1 in. U.H.) 1

99 14 66',t0 lnner cover screw (1+ in. U.H.) 4
100 14-6606 lnner cover screw (; in. U.H.) 2
101 E8'132 v nng 'l
102 'F99 1056 Auto-advance un it (54416405) 1
103 D995 Condenser 1
104 E7788 Contact breaker 1
105 99 0072 Points (54419827) ... ... 1
106 14-0208 Contact breaker bolt ... 1
107 E8163 Washer ... 1
'108 E4747 Clam p pillar bolt 7
109 E8164 Washer ... 2
110 E8166 Contact breaker lead sleeve ... 1
*Spring set only 99-1011 (54417992)
21
l
\ 18
Fis.4. CLUTCH AND PRIMA,RY CHAINCASE
22
Ref. No. Port No. DESCR/PIlON
QUANI/T}'
CLUTCH AND PRIMARY CHAINCASE

1 r2166 Screwed plug
2 E8782 "O" ring... 2
1
3 E11058 Primary chaincase cover

1
4 E9800 Filler plug
5 s2002
I
Level plug
1
6 E7856 Chaincase gasl<et
1
7 14-6611 Cover screw (1f in. U.H.;
I 14-6610 Cover screw (1j in. U.H.)
4
5
9 s'1951 Cover screw (1{ in. U.H.)
1
10 E8175 Washer ... 'l
11 E8010 Chaincase dowel
z
17 D951 Primary chain (70L)
1
13 E8'17 6 lgnition pointer ...
1
14 E8955 lnspection cover ...
1
J5 E8178 Gasket
1
16 E8177 Screw (f in. U.H.) 4
17 r2v3 Clutch hub
1
18 T2714 Clutch hub key ...
1
19 T2715 Clutch spider
1
20 17716 Sprocket and housing 'l
21 T27',t9 Rolle r
25
22 T2720 ln ner retaining plate
1
23 s1943 Drain screw
1
24 r2721 Outer retaining plate
1
25 T2727 Screw (.i+ in. U.H.)
4
26 r2723 Shock absorber rubber drive and rebound
27 r2724 Centre
I
1
28 r2725 DriYen plate
5
29 r2726 Driving plate
4
30 r2727 Spring
4
JI T395'1 cuP 4
r2748 SprinS nut
4
33 T4019 Pressure plate
1
T7729 Adjuster... 1
35 F879 Locknut ... ,|
36 T2730 Retaining nut
1
37 r2731 Plain washer
1
38 r2732 Lockwasher
1
39 99-1006 Stator (47205)
40
I
s1894 Generator stud rear (2-j| in.) ...
1l Keler
40 s1895 Generator srud front (zti in.) , I- Page 13
40 s1896 Generator stud bottom (2{{ in.) I I also
41 E8072
1)
Washer
3
42 14-0901 Nut
3
---
45
./.-.--'
(,' a o
\
\,1 e
- -/
(Ot
-_--> 33
@-34
\tfi-
@N
.4t,<"
o*
'12
a_.-un
6
BK<Ys-'.
Dz', \lri 9
8/
\Y
@ JJ
-P6*,
50 53
Fig. s. FRAME COMPLETE
74
Ref. No. Port No. DESCRIPflON QUANTITY
FRAME
I F11607 Frame complete .., ... 1
2 F8994 Swinging arm spindle ... ... ... 'l
3 F8995 Spindle nur 1
4 F8996 Spindle washer ... ... ,|
F8819 Engine shield 'l

6 14-0113 Bolt (l in. U.H.) 7
7 E8134 Washer ... 2
B F9084 "P" clip ... 1
9 F9023 Bolt ({f in. U.H.) ,|
10 w1691 Nut I
1'l E8088 Washer ... 1
1). F9745 Engine steady stay I
13 F5535 Bolt (l-i in. U.H.) 3
14 s25-2 Plain washer 3
15 E8194 Nyloc nut 3
F8988 Ball head cup 2
F8984 Front engine fixing bolt (3fr in. U.H.) 1
18 s1934 Bottom bolt (7i in. U.H.) 'l
't9 E8084 Spacer 2
70 Eq't94 Nyloc nut 'l
21 E8'l 33 Nut 2
22 E8134 Shakeproof washer 2
23 F8985 Rear stud (2fr in. O.A.) 1
24 F8986 Spring washer 2
25 F8987 Nur 2
26 99-0719 Battery (54027029) type PUZ5A 1
77 D980 Battery vent pipe 1
28 F8285 Battery carrier ... ... 1
29 F9003 Battery tray rubber 1
30 F9004 Hool< 1
31 F9005 Battery strap 'l
F9006 Bolt (11f in. U.H.) 2
33 F9007 Mounting rubber 4
34 F9008 Washer ... 2
35 E8137 Nut 2.
36 F9086 Bolt (3 in. U.H.) ... I
F9007 Mounting rubber 2
38 F9087 Spacer I
39 F9010 Washer ... 3
40 E8'194 Nyloc nut 1
4'l F9090 Tool tray c/w clips 1
Not illus. F9't57 Plug fcr tool tray 1
42 F909'l Bolt (.641 in. U.H.) 1
43 F9092 Spacer 1
44 F8071 Nut 1
45 F9060 Bolt ($ in. U.H.) ... I
46 E8072 Washer ... 'l
47 E8071 Nut 1
48 F9094 Bracker ... I
49 F9093 Rubber buffer 1
50 F994s Silencer mounting bracket 1
25
n,' .gi'
*5 1u ou
"ufu""
V'"n F"
o6 QYq=<f$=< 2e
\ \.'. l/ .1, \F e-..

42\Eil
\r'
9--- 43
.3\
'44
l\
(<t
"'t%
52
/\
50 53
Fig. 5. FRAME COMPLETE
Ref. No. Port No. DESCR/PIlON QUANTITY
FRAME continued
5'l 14-0115 Bol! z

52 w2320 Sprint washer ... ,.. 2
53 14-0302 Nut z
54 F9ZZ2 Tank anti roll rubber ... ... 2
55 E8189 Steady stay bracket 1
p.-
5@
4
,@
7
Fig.6. S\iVINGING ARM AND SUSPENSION UNITS
28
Ref. No. Port No. DESCR/PIION' QUANI/TT
swt NGING ARM AND SUSPENSION UNITS

1 F9z',t0 Swinging arm 1
7 F8993 Silentbloc z
3 D7067 susPENstoN uNtT (64054927) 2
4 99-1057 Spring (64543626) ... .. 2
5 99-0107 Spring retainer (90541171\ 2
6 99-o',tzt Bonded bush-top (64533645) z
7 99-1058 Bonded bush-bottom (64533654) 2
8 F8997 Unit fixing bolt (1* in. U.H.) ... 7
F8998 Plain washer 2
'10 s1-52 Nut 2
11 14-0903 Nut 2
12 F8933 Dust cover 7
13 F t1606 Propstand leg I
14 F3097 Swivel pin 1
IJ F3096 Lockwasher 1
't6 F26'10 S pring 1
17 F9950 Chainguard 1
'18 F9060 Bolt (1jf in. U.H.) I
19 E8071 Nut 1
20 14-0113 Bolt (1jf in. U.H.) 1
21 s25-2 Plain washer 1
22 1+1902 Nut 1
29
38
"oBE
*- \lE
27
14
29
4
t
@) 3
%
6^{1e@
w@
Fig.7. OIL TANK, PANELS AND EXHAUST SYSTEM
30
Ref No. Port No. DESCR/PTION QUANI/IY
OIL TANK, PANELS AND EXHAUST SYSTEM

'l E11181 M uffle r
2 E2271 Fixing clip
3 1+0219 Bolt ('lf in. U.H.)
4 E37 68 " D " washers
5 s26-3 Washer ...
6 s1908 Nut
7 F9019 Bolt $ in. U.H.)...
8 F9020 Spring washer
F879 Nut
10 E',t1121 Heat shield
'11 Et't722 Support strip
12 El1223 Distance piece ... ...
13 1+2206 Heat shield screw-rear
14 't+2205 Heat shield screw
't5 s25-43 Heat shield washer
16 D2338 Backing washer-front ...
17 E11178 Exhaust pipe
18 F8976 Finned collar
19 F8977 Screw (-ff in. U.H.)
z0 F8978 Nut
21 F11648 Oil tanl< ...
27 F9067 Bolt (1i in. U.H.)
23 F9068 Nut
24 F6039 Rubber sleeve
25 Fl1651 FTLLER CAP C/W D|PSTICK AND WASHER
26 F907 6 Washer
27 F8874 Banjo
28 F9070 Fibre washer
79 F9071 Filter
30 F9146 Rubber connection
31 F907 3 Clip
32 F9224 Rubber connection
33 E5473 Clip
34 E8106 Rocker oil. feed pipe
35 E8111 Clip
36 F9127 Ru bber sleeve
37 F8614 Panel D/S
38 D1006 Oddie stud
39 D983 Stud rubber
40 D2380 Panel motif D/S ...
41 D2380 Panel motif T/S ... ...
47 s771 Oil tanl< botrom fixing bolt
26
@ 2a
&P
24
*
.\i "
a---
I
b,oA
&f 0 a,
to 37
F
21
re *l--b
32Y,6{f"
/,
35
G
5
/P
)
,,
@ 6nr'
%
% d6^.
11
9-,o
Fig.8. FOOTRESTS AND BRAKE LINKAGE
Ref, No. Port No. DESCRiPTiON QUANTITY
FOOTRESTS AND BRAKE LIN KAGE

1 F9031 Rear brake pedal 1
w2326 Grease nipple 1
2 F9032 Fulcrum pin 1
3 F9033 Nut 1
5 E8193 Bolt (f in. U.H.) ... 'l
6 s26-t Spring washer 1
7 F9035 Plain washer 1
8 F9036 Rear brake rod ... 1
9 wF32 Pivor pin ... 1
10 F8072 Washer ... 1
10A D2683 Split pin ... 1
1',| F9958 Brake pedal srop 1
12 F9038 Swivel pin 1
13 F9039 Adjuster nur 1
14 F9040 Pedal stop ...bolc 2
15 F9041 Shakeproof washer 2
16 F9042 Nur 2
't7 F9043 Folding footresr ... ... 2
18 F11426 Foocrest hanger D/S 1
19 F11428 Footresr hanger T/S 1
20 F9044 Anchor bolt 2
21 E8084 Plain washer 7
22 F9045 Bolt (2j-f in. U.H.) 'l
74 F8986 Spring washer ... ... 1
25 F8987 Nyloc nut 'l
26 F9085 Nyloc nut 2
27 F9051 Foorrest rubber... ... 2
28 F9057 Bolt (1| in. U.H.) 2
29 F8137 Nut 7
30 F9053 Pillion footrest ... ... 7
31 F9054 Footrest rubber... ... z
32 F9044 Anchor bolt T7S ... ... 1
32 F9055 Anchor bolt D/S 1
33 F9085 Nut 2.
34 F9057 Boh (1| in. U.H.) 2
E8137 Nut 7
36 F9133 Pillion footrest support bracket T/S .., 1
37 14-0116 Bo lt 3
38 14-0707 Nuc 3
33
24
B
43 -d\\
*-'-A)
42-'e
41
r;)
s2{-)
ll- sa ( <---.)
22, sa g ]H,
!,:33S
fa:A d)-.-53
60
gis__/$,,
36
10
35 11
34
L
(o)
dP
26
15 &-,u
s
16
17 n
n2s
.l l- 30
1a E
l)- sr
(J.---:rz
t,@L
w
6 --
Fis. 9. TELESCoPIC FRONT FORK
Ref. No. Port No. DESCR'PIiON QUANTITY
TELESCOPIC FRONT FORK

H3895 FORK ASSEMBLY 1
'l H2294 D.S. BOTTOM MEMBER c/w cAP 1
7 H2295 T.S. BOTTOM M EI4 BER C1W:AP 1
3 H1844 Spindle cap z

4 1+02'.t8 Cap bolt 4
5 s26-3 Spring washer ... 4
6 H5t9 Drain plug ... ... 2
7 H430 Drain plug washer ... 2
8 H3694 Top cover T/S 1
9 H3693 Top cover D/S 1
10 H 3638 Spring support 2

1'l HZ63Z Sealing washer 4
17 H2633 Sealing washer 7
13 H2513 Gaiter 2
14 H3678 Main spring ... ... 2
15 H1656 Spring support washer 2-
't6 H'1500 Oil seal 7

17 H3639 LOWER COVER TU BE eiseMgiv 2
18 Reference only Sleeve.., Not supplied
separately
19 H7119 lJ flng z
20 H431 Outer washer 7
21 H441 Upper bearing 2.
H3677 lnner sleeve 2,
H2745 Top nut 2

24 H2653 Washer 2
25 H3906 Stanchion 2
76 H443 Lower bearing 2
77 H7',154 Shuttle valve z
28 H2091 Nut... 7
29 H7127 Circlip 2
30 H2090 Restrictor,... 7
31 H1062 Sealing washer 2-
37 H2126 Flanged bolt 2

H763'.| Spacer 7
34 H2630 Washer 7
s785 Pinch bolt ... ... z
36 s25-2 Washer 2
1+0303 Nut ... z
38 H7526 Middle lug and stem 1
39 H2648 Bottom cone I

40 H2525 Top lug 1
41 H2658 Cable gulde bracket 7

42 H7659 Grommet ... .,. z
43 H2645 Bolt (1+ in. U.H.) 1
44 H2646 Nut ... 7

45 H2656 Bolt ... 4
46 F8981 Was he r 4
47 H265s Handlebar clip 7
48 H2651 Sleeve nut ... ... 1
49 H2654 Cable guide ... ... 1
50 H2704 Steering head ball ... 40
35
4E
x-_ 47
43fu 46- u^ \
42.
a-a
-.:'G)
41
6A
It- s4
58g
d 17:-51
59
#B"
,/;
5' d4- 56
35
34
@
Jf
^fi-o'
@'"
s. -29
il^
J L-"o
Er'
i9'-- ar
S=- ",
ry
6 F.
Fig. 9. TELESCOPIC FRONT FORK
Ref, No. Pdrt No- DESCR/PrloN QUANI/IT
TELESCOPIC FRONT FORK continued
JI H2647 Top cone 1

52 H2650 Dust cap 1
53 H3746 Mounting bracker 1
54 14-0218 Bolt 1
55 14-0707 Nut 'l

56 't4-6102 Bolt 1
57 s26-2 Spring washer 7

58 E8088 Spacer 1
59 H2237 Heat sink ... ... I

60 H2775 Zener Diode sealing plug 1
61 H3926 Square nut 2
37
Fig. 10. FRONTWHEEL
38
Ref. No. Port No. DESCR/PTiON QUANTITY
FRONT WHEEL
w3465 FRONT WHEEL COMPLETE 'l
w7137 RII4, SPOKES AND HUB ASSEMBLY 1
1 w1230 Rim... 1
2 w3325 Hub 1
3 w2137 Spoke D/S 8 SWG x 6 in. straight 20
3 w21 38 Spoke T/S 8 SWG x 51f in.76' ... 10
3 w2139 Spoke T/S 8 SWG x 5$ in. 100" 10
w2136 Spoke n ipple 40
5 w653 Bearing 7
6 w1237 Dust cover 1
7 T280 Circlip 1
8 w3582 Wheel spindle ... ... 1
9 w1481 G rease cap D/S ... 1
l0 w3443 Cover plare 1
11 w3337 Bearing supporr ring 1
17 w582 Bearingretainer... ... 1
13 w3429 Anchor plate 1
14 w3444 Gauze 'l
15 s1998 Screw 3
16 F235'l Washer .. . 3
17 w2026 Brake abutment pad 2
w2001 Brake cam z
't9 w3453 Bral<elever-front 1
20 w3454 Brake lever-rear 1
21 w7027 Washer ... 2
22 14-0403 Nut 2
23 w3522 Return spring 1
24 w3450 Brake rod 1
25 w200s Fork end-threaded 1
26 14-040'l Locknut ... 1
27 WF32 Pivot pin ... ... 2
28 D2683 Split pin ... z
29 s1995 Nut 1
30 w3446 BRAKE SHOE C/W LINING... 7
3l Rel on ly Lin ing z
37 Ref. on ly Rivet 16
33 w1 35 Spring 7
34 w1't97 Balance weight + oz. A.R.
34 w1198 Balance weight 1 oz. A.R.
39
12
.14
Ag@,)
W
21
^v'^ ^
(w* \ :--\
a-(J
Fig. tl. REAR \^,HEEL
Ref. No. Pdrt No- DESCR/PIlON QUANTITY
REAR WHEEL
w3581 REAR WHEEL COMPLETE (LESS BRAKE AND TYRE) '1 with 49 T sprocket
w3452 REAR WHEEL COMPLETE (LESS BRAKE AND TYRE) 1 with 52 T sprocket
w2290 RII'4, HUB AND SPOKES ASSEMBLY 'l
,|
w2297 Hub com plete 1
2 w2792 Spoke D/S 20
w2293 Spoke T/S 70
4 w2794 Nrpple... 40
5 w2291 Rim 'l
6 w2309 Fixed spindle nut ... 1
7 w2339 Chain adjusrer 7

8 w1015 Chain adjuster end cap 7
9 E8137 Adjuster nu[ 2
10 E8088 Adluster washer 2
11 w2335 Brake anchor strap 1
12 w2336 Bolt (1{ in. U.H.) ... 1
13 w2337 Washer 1
14 F9085 Nut 1
15 w2325 Fulcrum pin nut 1
16 w2324 Fulcrum pin washer 1
17 w2323 Fulcrum pin 1
18 w2372 Brake anchor plate 1

19 w2327 BRAKE SHOE COMPLETE WITH LINING 2
20 Reference on ly Brake lining ... ... Nor serviced
71 Reference only Bral(e rivet
2
'14
/
\separately
22 w2328 Brake shoe spring ... 7
23 w2329 Brake cam lever 1
24 w2226 BRAKE CAM 'l

25 w2326 Grease n ipple 1
26 w2334 Brake lever retu rn sprint 1
27 w2330 Plain washer 1

28 w2331 Shakeproof washer 1
29 w2332 Nut .. . I
30 w2317 Locking ring 3
31 D1028 Rear chain (t x I x 1011) ... ... 1 East coast
31 D't023 Rear chain (! x { x 991) ... ... 1 West coast
32 w2314 Driving flanSe 1
33 w2312 Bearint sprint ring... 1
34 w2311 Bearing shim 1
35 w2315 Bolt ... 6

36 w2316 Nut ... 6
37 w2308 Fixed spind le 'l
38 w2305 Bearint retaining ring 1
39 w7798 Bear ing z

40 w2299 Thrust washer 1
41 w2313 Washe r 1
42 w2363 Bearing 1
43 w2300 Sp.nd le sleeve 1

44 w3468 Securrty bolt WM3 .. 2
45 w2318 Brake drum... ... I
46 w2354 Chainwheel (52T) ... 1 East coast
46 w2321 Chainwheel (49T) ... 1 West coast
47 w2319 Chainwheel bolc 10
41
12
M W
,14
^i.n
(w"
\
o-
Fig. tt. REAR wHEEL
Ref No. Port No. DESCRIPTION QUANTiIY
REAR WHEEL continued
48 w2320 Sprint washer 10

49 w2302 lnner retainer I
50 w2301 Felc washer 1
51 w2303 Outer retainer 1
52 w2304 Hub end cover 1
53 D1026 Speedometer gearbox (BG5330/31) 2 : 1 1
54 w2306 Disrance collar inner O/S... ... 1
55 w2307 Distance collar outer O/S 1
56 w2333 Hub spindle 'l
%^*-.,o 1s
ffwt" 'eb
)iu
6)
p ),)
tle)
'oKT-----,,-
24 (y ,d'"
/(r, /
d ',
. I \}/
6 '-"n4
wqq" *0 o,,
Fig. 12. FENDERS
44
I
Ref. No. Pcrt No. DESCR/PTlON QUANTITY
FENDERS
1 H1674 Front fender
2 H1681 Front stay
3 H1683 Bridge stay
4 H3683 Bottom stay
F9019 Bolt (+ in. U.H.) ...
6 F9068 Nyloc nut
7 F9079 Bo lt
8 E8088 Washer ...
9 w1691 Nut
10 F9017 Bolt ({ in. U.H.) ...
11 w1591 Nut
12 14-0114 Bo lt
13 s25-3 Plain washer
14 GS299 Washer ...
15 1+0702 Nut
16 F9506 Rear fender
17 F9019 Bolt (] in. U.H.) ...
18 F9027 Special washer ... ...
19 F9020 Spring washer ... ...
20 F879 Nur
21 F9023 Bolt (j{ in. U.H.)
22 E8088 Washer ...
23 E8137 Nut
24 F9028 Wiring grommet
25 F11 335 Rear fender support rail
26 F8'139 Tail lam p support
27 E2980 Stud (lf ln. o.A.)
28 F9132 Support plate
29 s25-1 Washer ...
30 F9030 Spacer
31 T3638 Spacer
F9068 Nut
33 F11529 Rear number plate bracket
34 F9019 Bolt (j in. U.H.)...
35 s25-'l Washer ...
36 E8071 Nut
37 H1685 Bracket ...
38 s1822 Bo lt
10 F4299 Washer ...
40 F4715 Screw
41 s5161 Nut
7 21
G,
-4
/\\
wr \t/'
3
ll
22 24
,<'%.'"
2oA-)
20 (g)
18
-25
23
(6&/
ll .,' 16
-"
't9 T
17
m-F 2A
Fis. 13. cAS TANK AND T\r/IN SEAT
Ref No. Port No. DE5CR/PIlON QUANI/IY
GAS TANK AND TWIN SEAT

1 F9479 Gastank ... 1
2 t9690 Mounting rubber-rear 1
3 t9't34 l'4ounting rubber-front 1
4 F10759 Bolt (1* in. U.H.) 1
5 F9063 Distance tube z

6 Fl0250 Distance tube 1

9 E8196 Nut 1
10 F9480 Trim strip 1
1'l t4715 (-jf in. U.H.)

Screw 2
17 H430 Washer ... 2
124 H430 Washer ... 7
't3 F9700 Styling unit T/S ... 1
13 F970'l Styling unit D/S 1
14 F8192 Knee grip D/S ... 1
15 F8193 Knee grip T/S 1
16 F8946 Styling it screw-front

un 7
17 F7888 StylinS unit screw-rear 7
't8 F9769 Gas line ... 1
19 F4971 Gas tap ... 1
19 F4972 Gas tap-withreserve ... 1
20 E735',1 Gas tap washer (Stat-o-seal) 2

20A F10002 Steel washer ),
21 F3220 Filler cap 1
27 F9744 Tie bar 1
23 s5662 Bolt (; in. U.H.)... 7

24 E8088 Spacer 4
75 w2320 Spring washe_r 2
26 F9472 Twin seat (cover F9504) 1
77 F11527 Trim strip 1
28 D697 Sprags As req uired

29 F9476 Rear fixing bracket I
31 E8101 Nut 2
32 s602 Plain washer 7
33 Ft't304 Handrail ... 1
34 F9023 Bolt (+* in. U.H.) 2

35 E8088 Washer ... 2
36 w1691 Nut 2
47
\N-tf
g
E'
Ntav
P G)\
w
.17
33
ffi-'1a
's
@
\.
Fig. 14. HANDLEBARS, CONTROL LEVERS AND CABLES
Ref, No. Port No. DESCR/PIlON QUANTITY
HANDLEBARS, CONTROL LEVE RS AND CABLES

1 H7628 Handlebar-Western type 'l
99-0248 TWTSTGRTP (161364) ... ... 'l
7 D958 Handlebar gr ip 'l
3 99-0245 Body top half (16/328) 1
4 99-0246 Body bottom half (161329) 1
5 99-0744 Rotor (16/09'1) 1
6 99-0238 Friction sprint (6/008) ... I
7 99-0239 Friction spring screw (16/009) ... ... 1
I 99-0240 Nut (16l010) 'l

9 99-0726 Screw (1 I /014) 2
10 99-0241 Cable stop (16/011) 'l
11 D959 Dummy grip 1
D2243 FRONT BRAKE LEVER (ball end) (19/1098) 1
1Z 99-0767 Lever bracket (19/003) 'l

't3 99-0262 Lever (12l754) 1
14 99-0252 Fulcrum prn (181087) 1
15 99-0250 Fulcrum pin nut (18/053) ... ... 1
16 99-0226 Clamp bolt (11/014) 2

'17 99-0230 Control clip (12/595) 1
18 99-1031 Cable ad1uster (18/1708) ... 'l

't9 99-1059 Cable adjuster locknut (18/1709) 1
D2742 cLUTCH LEVER (ball end) (18/9s2) 1
20 99-1176 Bracket (19/002) ... ... 1
21 99-0261 Lever (18/752) 1
22 99-0230 Control clip ('12/595) 1
23 99-0252 Fulcrum pin (18/087) 1
24 99-0276 Clamp bolt (11

/014) 2
25 99-0250 Fulcrum pin nut (18/053) 1
26 99-1031 Cable adjuster (18/1708) ... 1
27 99-1059 Cable adjuster locknut (18/1709) 1
28 D962 IHROTTLE CABLE 'l

29 D2034 FRONT BRAKE CABLE 'l
30 D2085 Front srop switch .,. I
31 D2086 Rubber cover 1
37 D963 Cable toggle end ... 1
33 D964 Toggle end screw ... 'l

34 D965 Toggle end nut 1
35 D2083 CLUTCH CABLE 1
49
.lL
,u.-
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26 I\
V
ll
tl
u
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@-""
u--@
,-@
tg \.
'o '--eb
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,12
Fis. 15. SPEEDOMETER AND TACHOMETER
Reji No. Port No. DESCRIPIION QUANTITY
SPEEDOMETER AND TACHOMETER

1 D1949 Tachometer (R.S.M. 3003/01) ... ... 1
2 D2173 Ca ble 1
3 H3689 Mounting plate ... 'l

5 F9't71 Screw 4
6 t9177 Washer .. . 4
7 F9173 Nut 4
I F9174 Bush 4
E9428 TACHOMETER GEARBOX COMPLETE 1 Optional
9 E9517 Drive body ... ... 1
10 E9381 Drive shafr ... ... 1

11 E9382 Drive gear ... ... 1
12 E9429 Retaining pin-drive gear I

13 E9383 Thrust washer 1
14 E9430 "O" ring 1

'15 E943',1 Locating pin 1
16 E9432 Joint washer 1
17 D2296 SPEEDOMETER 12s r.4PH (SSM s00/03) 1
18 F8283 Speedometer mounting plare assembly ... ... 1

'19 F10281 Speedometer mou nting cup 1
20 F917'l Screw 4
21 F9174 Bush... 4
22 F9172 Sprint washer
23 F9173 Nut ... 4
24 D692 Cable 'l
643 Bulb 7
99-0695 Bulb holder (554710) 1
51
-
100
12
li
/'R / \'1,
t/\\ I
\\)t\ t)F
\ uuR c?
,l+r
_
.=-J
\Y4 \'/ 5
dF,,
25
162*
ffi Eow
.6
9..-""
43
(
*"b 41 s6
"i-- d ----,afF- m* 17
m) (
\({
" ))2
\--=-z &
)5
^l:i.-
(.)
\+u
4 5
w,"
Fig. t6. ELECTRICAL EOUIPMENT
Ref No. Part No. DESCRIPT'ON QUANTITY
ELECTRICAL EAUIPMENT
D2261 HEADLAMP ASSEMBLY (s4052910) ... ... 1
I 99-0691 Rim (534343) 1
2 99-'t041 Light unit (54524526\ I

3 99-0683 Fixing wire (504665) ... ... 6
4 99-1047 Bulb (40/27W pre-focus) (464) . 1
5 99-1003 Adaptor c/w leads (54520540) 1
6 99-1004 Bolt (112201) 2.

7 H't932 Spacer 2
8 144921 Screw Ref. only
9 55408 Plate ... Ref. on ly
10 99-0563 Lighting switch (35710) ... 1
't'l 99-0556 Dip switch (31620) 1
12 99-0568 Warning light (Red) 1
13 99-0537 Bu lb (2w BAT5) (281) z

14 99-0803 Warning bulbholder (54945043) Rel only
15 99-0548 Pilot bu lb (989) 1
16 99-0695 Pilot bulbholder (554710) 1
17 54190108 Double Lucar blade Ref. only

18 99-1053 Harness (54955718) ... 1
19 Reference only Stop-tail lead 1
20 99-0589 Rectifier c/w securing nut 1
99-0597 sToP AND TArL LAMP ASSETT4BLY (53973) 1
21 99-0781 Lens (54572932) 1
22 99-0698 Screw (572289) 2

73 99-0542 Bulb (5/2lW offset pin) (380) 1
24 54574348 Bulbholder with refl ector Ref. on ly

75 54578213 Bracker Ref. on ly
76 573828 Contact assembly ... ... Ref. on ly
77 99-0780 Gasket (54571677) 1
28 F4715 Screw 2
19 GS299 Washer 2
30 F8307 Stop and tail lamp lead tube ... 1
31 F8972 Front reflector c/w bracker 2

32 F8318 Ducon horn push (WIPAC '16714) 2
t8273 Rear reflector 2
34 F8140 Rubber washer 2
35 F8195 Push-Fix ... 4
36 D992 Horn I
37 F5535 Bolt 1
38 E8'191 I
39 E8084 Spring washer 1
40 E8194 Nut 1
41 D7240 coil (4s221) 1
42 F11603 Coil support clip 1
43 1+0204 Bolt ('1t in. U.H.) 1
44 s602 Washer ... 1
45 F t1578 Distance piece .., ... ... 1
53
-//
t-/ @
,ll|',-
\y
&,,
te\
M:,^
t/
'// ^20
-J/ftl
"==:r/ CD
2l
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AP'n A nM '""$wcl(
\-P \J'tr- "-<v-
T\9: 25
oo
"Lr-+ 33
"9
34
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\,/
43
42 .ob
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4l
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(^---\Sa-
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")P (s
r^ ,/
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ral":A45
r\frd\
,x),#^
\ls 52 -,P"e
s4 53 I
An
Fit 16, ELECTRICAL EOUIPMENT
54
l--
Ref. No. Port No. DESCR/PTiON QUANI/IY
ELECTRICAL E QU lP MENT continued
46 14-0801 Nut 1
47 Reference on ly H.T. lead 1
48 99-0590 Zener diode (49345) 1
49 D1000 lgnition lock C/W keys I

50 99-0558 lgn ition switch (3'1899) 1
51 99-1000 rGNrTroN swrTcH NUT (54130041)... 1
52 D990 Rear stop swicch (34815) 1
53 F9191 Bo lt 7
E9122 Cable slip (stop switch) 1
56 D999 H.T. lead grom met I
55
f.
F
10
H
Fig. 17. TOoL KIT
Ref. No. Port No. DESCR/PflON QUANIIIY
TOOL KIT
D2113 TOOLROLL COMPLETE WITH TOOLS I
1 D291 Toolroll 1
2 D968 Suspension unit spanner ... ... 1
3 D801 Combined tyre lever and tommy bar 1
4 D87 Plug span ner 'l

5 D767 Screwdriver set 1
6 D2084 Span ner 1
7 D97',| Box spanner 1
I D972 Ring spanner 1
NA144 Tyre lever ... ... 1
10 D974 Tyre valve key 'l

11 D978 Cable clip-rubber
12 X469 Cable clip 3
13 D1079 Cable clip 5
14 H2654 Cable clip-wire I
57
.-
K
{9
6,--g,
\l-,
o
Ft---
M
1a
\
@r.'---'-l
ruT
v
Fig.'18. CARBURETOR
58
T
I
Ref. No. Pdrt No. DESCR/PIlON QUANIIIY
CARBURETOR
D70ZZ CARBURETOR COMPLETE (R928/4) 1
1 99-0521 Screw and washer (622/086) 4

7 99,0221 Plug screw (41137A) 1
3 99-0531 Top cap (928/097) ... ... 1
4 99-0507 Th rorrle sprint $271061) ... I

5 99-0510 Circlip (6221067) ... ... 1
6 99-0529 Need le (928/063) ... ... 1
7 99-0527 Throule valve (3) (928/060) 1
I Reference only Body ... 1
9 99-0444 lYainjet (160 c.c.) (376/100) 1
10 99-0516 Throttle stop screw (6771077) ... 1
11 99-0515 Pilot air screw (6221076) ... 1
12 99-0520 ''O" ring (6221082) z

13 99-0522 ''O" ring (622110'l) 1
14 99-0514 Gasket (6221073) ... ... 1
15 99-0518 Need le jet (6221079) 1
16 99-0519 Jec holder

(6221080) 1
17 99-0517 Float (6221069) 1
18 99-0513 Floar spindle (6221071 ) 1
'19 99-0511 Floar needle (6221068) 1
20 99-0506 Float chamber (622/050) ... 1
21 99-0438 Filcer (376/093) I

27 99-0517 Banjo bok (6221078) 1
23 D1053 AIR CLEANER COI'4PLETE ... ... 1
24 F9194 Air cleaner element 1
59

Triumph 99-0906 1970 Tr25w Trophy 250 X

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REPLACEMENT

TRIUMPH ENGINEERING COMPANY LIMITED

P..t No. 99-0906

THE FITTING OF ANY COMPONENTS WHICH ARE NOT APPROVED BY THE

AIR FILTER ... 59 OIL PUMP ... 15

PILLION FOOTRESTS ... 33

FRONT FORKS ...35,37 TAIL LAMP ... 52

GASKET SETS ... 7

GEARBOX 17, 't9, 11

VALVES ... 9, 1'l

MUFFLER 31 ZENER DIODE 55

Capacity ... -.. 249 c.c.

Compression ratio 9.6:1

Sparking plug Champion N3

Carburetor Amal Concentric .928

Gearbox sprocket 15 teeth

Final Drive Sprocket 52 teeth East Coast

Brakes Front and rear diameter 7 in.

Tyre size ... ... Front 3.25 x 18

CARBURETORS. The Avon lndia Rubber Co. Ltd.,

SPECIAL WORKSHOP TOOLS

UNIFIED TH READ FORM

E7998 9.6 : I C.R. STANDARD SIZE

PA RTS VARYING FROM STANDARD SIZE

PISTON RINGS 1 E8177 Top compression ring

PISTON RINGS 1 E8278 Top compression ring

Big end bearing undersizes 0.010 in. Part Number E6068/10

CYLINDER HEAD, BARREL AND CRANKSHAFT

z E9849 C ran kshaft Reference only

*Refer page 7 for oversizes.

Fis. l. CYLINDER HEAD, BARREL AND CRANKSHAFT

CYLIN DER HEAD, BARREL AND CRANKSHAFT continued

43 E7911 Rocker box ... I

58 Dt002 PIug cover ... 1

2 E8006 Cylinder securint stud 2

8A E9974 Main bearing (roller bearing) 1

9 E8025 Oil seal left main bearint ... ... 1

10 s1894 Generator stud rear, short hexagon 1zg i".1 'l

13 E8315 Camshaft bush 1

73 12697 "O" ring 1

24 sl872 Timint hole plut... 'l

27 E8256 Sealing washer ... ... 1

36 E807'1 Plain washer 4

44 E9737 Joint washer 1

45 E8124 Non-return valve spring 'l

48 D2133 Oil pressure switch Alternative

49 D2045 Cover for oil switch 1

50 12695 Dipsrick ... 1

51 T948 Dipsticl( washer ...

52 E8147 Clip for alcernaror lead grommec 1

53 E8148 Alrernator lead grom met 1

54 E3789 Orl seal housing ... ... 1

56 E3833 Oil seal 1

59 E8173 R: bber pipe 1

61 E8072 Washer ... 1

62 14-1901 Nyloc nut 1

53 E8127 O'l pipcs and unron block 1

64 E8259 ''O" ring ... .. 2

67 E111 33 OIL PUI,IP COMPLETE 1

68 E11139 Spind le housing 1

70 E8094 Spind le gear 1

71 E8095 gear-driven ...

77 E1't143 Scavenge gear-driving 'l